U.S. patent number 8,074,591 [Application Number 12/442,944] was granted by the patent office on 2011-12-13 for embroidery using soluble thread.
This patent grant is currently assigned to NuVasive, Inc.. Invention is credited to Peter Butcher, Christopher Reah.
United States Patent |
8,074,591 |
Butcher , et al. |
December 13, 2011 |
Embroidery using soluble thread
Abstract
A manufacturing process and resultant medical devices and
components thereof wherein one or more individual laces (12) is
placed within an embroidered structure (10) using an automated
process allowing for the manufacture of embroidered surgical
implants containing laces to be mass produced repeatably and cost
effectively.
Inventors: |
Butcher; Peter (Nottingham,
GB), Reah; Christopher (Taunton, GB) |
Assignee: |
NuVasive, Inc. (San Diego,
CA)
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Family
ID: |
39230817 |
Appl.
No.: |
12/442,944 |
Filed: |
September 25, 2007 |
PCT
Filed: |
September 25, 2007 |
PCT No.: |
PCT/US2007/020782 |
371(c)(1),(2),(4) Date: |
March 25, 2009 |
PCT
Pub. No.: |
WO2008/039497 |
PCT
Pub. Date: |
April 03, 2008 |
Prior Publication Data
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Document
Identifier |
Publication Date |
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US 20100089297 A1 |
Apr 15, 2010 |
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Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
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60847022 |
Sep 25, 2006 |
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Current U.S.
Class: |
112/475.18 |
Current CPC
Class: |
D05C
7/00 (20130101); D05D 2209/00 (20130101) |
Current International
Class: |
D05B
93/00 (20060101) |
Field of
Search: |
;112/78,236,475.18,439,475.21,475.22,475.23 ;606/73 ;623/901 |
References Cited
[Referenced By]
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0744162 |
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2710520 |
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2276823 |
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WO 2004/002374 |
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WO |
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WO 2007/012070 |
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Jan 2007 |
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WO |
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Primary Examiner: Worrell, Jr.; Larry
Attorney, Agent or Firm: NuVasive, Inc. Spangler; Jonathan
Jarvis; Marjorie
Parent Case Text
CROSS-REFERENCES TO RELATED APPLICATIONS
The present international patent application claims the benefit of
priority from commonly owned and co-pending U.S. Provisional Patent
Application Ser. No. 60/847,022, entitled "Embroidery Using Soluble
Thread," filed on Sep. 25, 2006, the entire contents of which are
hereby expressly incorporated by reference into this disclosure as
if set forth fully herein.
Claims
What is claimed is:
1. A method of manufacturing an embroidered structure having at
least one embedded lace element, comprising: providing a substrate
having a stitching surface and a backing surface, a plurality of
stitching threads, and a plurality of backing threads secured to
said backing surface and corresponding to said plurality of
stitching threads, at least one of said stitching threads and
backing threads comprising a lace thread and at least one of said
stitching threads and said backing threads comprising a soluble
thread corresponding to said lace thread; stitching together said
stitching threads and said corresponding backing threads through
said substrate to form a plurality of thread pairs including lock
stitches forming a two-dimensional embroidered structure; stitching
together said lace thread and said corresponding soluble thread
through said substrate to form at least one temporary thread pair
forming a part of said embroidered structure; and dissolving said
soluble thread such that said lace thread becomes unpaired yet
embedded and free to move within said embroidered structure.
2. The method of claim 1, further comprising the step of: enclosing
said plurality of thread pairs and said at least one temporary
thread pair within at least one plurality of enclosing thread
pairs.
3. The method of claim 2, wherein said enclosing thread pairs are
formed by stitching a plurality of enclosing stitching threads and
a plurality of corresponding enclosing backing threads through said
plurality of thread pairs and at least one temporary thread
pair.
4. The method of claim 1, further comprising the step of removing
said substrate.
5. The method of claim 1, further comprising tensioning said at
least one unpaired lace thread to maneuver said two-dimensional
embroidered structure to form a three-dimensional embroidered
structure.
6. The method of claim 5, further comprising tying the ends of the
tensioned at least one unpaired lace thread to secure the form of
said three-dimensional embroidered structure.
7. The method of claim 5, wherein said two-dimensional embroidered
structure comprises a generally circular shape, and tensioning said
at least one unpaired lace thread results in the formation of a
generally dome-shaped three-dimensional embroidered structure.
8. The method of claim 5, wherein said two-dimensional embroidered
structure comprises a quadrilateral, and tensioning said at least
one unpaired lace thread results in the formation of a
three-dimensional cylindrical embroidered structure.
9. The method of claim 5, wherein said two-dimensional embroidered
structure comprises a plurality of contiguous quadrilaterals, and
tensioning said at least one unpaired lace thread results in the
formation of a three-dimensional open box-shaped embroidered
structure.
10. The method of claim 5, wherein said two-dimensional embroidered
structure comprises a plurality of contiguous quadrilaterals, and
tensioning said at least one unpaired lace thread results in the
formation of a three-dimensional hexahedron-shaped embroidered
structure.
11. A method of aligning a series of objects, comprising: providing
a series of embroidered structures, each having plurality of
apertures and at least one embedded lace thread extending
continuously therethrough, said series of embroidered structures
manufactured by a process comprising: providing a soluble substrate
having a stitching surface and a backing surface, a plurality of
stitching threads, and a plurality of backing threads secured to
said backing surface and corresponding to said plurality of
stitching threads, at least one of said stitching threads and
backing threads comprising at least one lace thread and at least
one of said stitching threads and said backing threads comprising
at least one soluble thread corresponding to said lace thread;
stitching together groups of said stitching threads and said
corresponding backing threads through said soluble substrate to
form groups of a plurality of thread pairs including lock stitches
forming a series of two-dimensional embroidered structures;
stitching together said at least one lace thread and said
corresponding at least one soluble thread through said soluble
substrate to form at least one temporary thread pair forming a part
of said each of said embroidered structures forming said series;
and dissolving said soluble substrate and said soluble thread such
that said at least one lace thread becomes unpaired yet embedded
and free to move within and extending continuously through each of
said embroidered structures forming said series; fastening said
series of embroidered structures to a series of misaligned objects
by inserting a fastener through said apertures and into said
objects; and tensioning said at least one lace thread to cause the
lace thread to straighten and bring the objects fastened to the
embroidered structures into alignment.
12. The method of claim 11, wherein tensioning said at least one
lace thread comprises causing the ends of said lace thread to
migrate in opposite directions.
13. The method of claim 11, wherein said two-dimensional
embroidered structures are generally polygonal in shape.
14. The method of claim 11, wherein said at least one temporary
thread pair is stitched such that said temporary thread pair
zigzags between at least two of said series of embroidered
structures.
15. A method of using embroidery to create a woven structure,
comprising: providing a soluble substrate having a stitching
surface and a backing surface, a plurality of stitching threads,
and a plurality of backing threads secured to said backing surface
and corresponding to said plurality of stitching threads, each of
said stitching threads and corresponding backing threads comprising
one of a lace thread and a soluble thread corresponding to said
lace thread; stitching together said stitching threads and said
corresponding backing threads through said soluble substrate to
form a plurality of temporary thread pairs including lock stitches
forming a two-dimensional embroidered structure; and dissolving
said soluble substrate and said soluble threads such that said lace
threads become unpaired and inter-woven, transforming said
two-dimensional embroidered structure into a two-dimensional woven
structure.
16. The method of claim 15, wherein said woven structure includes
at least one of a honeycomb shape and diagonal weave shape.
17. A three-dimensional embroidered structure, comprising: a
plurality of contiguous embroidered polygonal panels, including a
base panel having a plurality of sides, each side comprising one
side of a secondary panel, each secondary panel including at least
one lace thread having two ends embedded therein, said at least one
lace thread continuously embedded and free to move through each
secondary panel, said plurality of embroidered polygonal panels
manufactured by a process comprising: providing a substrate having
a stitching surface and a backing surface, a plurality of stitching
threads, and a plurality of backing threads secured to said backing
surface and corresponding to said plurality of stitching threads,
at least one of said stitching threads and backing threads
comprising at least one lace thread and at least one of said
stitching threads and said backing threads comprising at least one
soluble thread corresponding to said lace thread; stitching
together groups of said stitching threads and said corresponding
backing threads through said substrate to form groups of a
plurality of thread pairs including lock stitches forming a
plurality of contiguous two-dimensional embroidered panels;
stitching together said at least one lace thread and said
corresponding at least one soluble thread through said substrate to
form at least one temporary thread pair forming a part of each of
said secondary panels; and dissolving said soluble thread such that
said at least one lace thread becomes unpaired yet embedded and
free to move within and extending continuously through each of said
secondary panels; tensioning said at least one lace thread to cause
said secondary panels to maneuver into a three-dimensional
orientation such that each of said secondary panels comes into
contact with at least one other secondary panel; and tying the ends
of said at least one lace thread together such that said
three-dimensional orientation is secured.
18. The three-dimensional embroidered structure of claim 17,
wherein said at least one lace thread comprises a plurality of lace
threads.
19. The three-dimensional embroidered structure of claim 18,
wherein said plurality of lace threads extend continuously through
each of said secondary panels generally parallel to one
another.
20. A method of guiding at least one thread element around a series
of obstacles, comprising: providing a series of embroidered
structures, each having plurality of apertures and at least one
embedded lace thread extending continuously therethrough, said
series of embroidered structures manufactured by a process
comprising: providing a substrate having a stitching surface and a
backing surface, a plurality of stitching threads, and a plurality
of backing threads secured to said backing surface and
corresponding to said plurality of stitching threads, at least one
of said stitching threads and backing threads comprising at least
one lace thread and at least one of said stitching threads and said
backing threads comprising at least one soluble thread
corresponding to said lace thread; stitching together groups of
said stitching threads and said corresponding backing threads
through said substrate to form groups of a plurality of thread
pairs including lock stitches forming a series of two-dimensional
embroidered structures; stitching together said at least one lace
thread and said corresponding at least one soluble thread through
said substrate to form at least one temporary thread pair forming a
part of said each of said embroidered structures forming said
series; and dissolving said soluble thread such that said at least
one lace thread becomes unpaired yet embedded and free to move
within and extending continuously through each of said embroidered
structures forming said series; and fastening said series of
embroidered structures to a series of obstacles by inserting a
fastener through said apertures and into said obstacle, thereby
allowing said lace thread to be anchored and guided around said
obstacles in a predictable path.
21. The method of claim 20, wherein said at least one thread
element comprises a plurality of lace threads.
22. The method of claim 21, wherein said plurality of lace threads
extend continuously through each of said series of embroidered
structures generally parallel to one another.
Description
BACKGROUND OF THE INVENTION
I. Field of the Invention
The present invention relates to medical devices and methods
generally aimed at surgical implants. In particular, the disclosed
system and associated methods are related to a manner of creating
surgical implants via embroidery.
II. Discussion of the Prior Art
Embroidered structures are created on substrates. Some substrates
are designed to stay in place with the embroidered structure while
other substrates are removed at the end of the embroidery process.
If the substrate is designed to be removed, the preferred method of
removal is dissolution. The dissolution processes discussed,
however, are not intended to preclude the use of other means of
substrate removal which those skilled in the art would employ in
the manufacture of an embroidered structure, or the omission of
substrate removal.
As an initial step in the creation of embroidered structures, a
plurality of parallel, stationary backing threads are placed and
secured on one surface of a substrate, called the "backing
surface." On the opposing surface of the substrate, called the
"stitching surface," is a plurality of stitching threads with
one-to-one correspondence to the backing threads. Stitching may be
done between one pair of threads at a time or in simultaneous
multiplicity, as is described below.
The plurality of stitching threads from the stitching surface are
passed to the backing surface through openings created in the
substrate by the passing of each individual thread. Each stitching
thread is then looped over its corresponding backing thread, in
essence picking up the backing thread, which creates a lock stitch.
Once each stitching thread has picked up its corresponding backing
thread, the plurality of stitching threads are returned to the
stitching surface by passing through the openings in the substrate
created by initially passing the stitching threads to the backing
surface. The lock stitches prevent the stitching threads from
completely pulling back out of the openings created in the
substrate. The plurality of stitching threads are then moved to a
new stitching site and the process repeats until all the backing
threads are joined by lock stitches to the corresponding stitching
threads, creating a plurality of thread pairs of some length.
A plurality of thread pairs may be enclosed by one or more
pluralities of enclosing thread pairs. To enclose a plurality of
thread pairs, a subsequent plurality of backing threads are placed
and secured on the backing surface of a substrate already holding
at least one plurality of thread pairs, such that the subsequent
plurality of backing threads covers the previously stitched
plurality of backing threads. A subsequent plurality of backing
threads is usually not parallel with the previous plurality of
backing and stitching threads. A subsequent plurality of stitching
threads, with one-to-one correspondence to the subsequent plurality
of backing threads, is then stitched to the subsequent plurality of
backing threads by the stitching process described above.
When the subsequent plurality of backing threads are all joined to
the subsequent plurality of stitching threads by lock stitches over
a desired distance, a plurality of enclosing thread pairs has been
formed, enclosing all previously stitched pairs. This process may
be repeated by stitching even further subsequent pluralities of
enclosing thread pairs over the previously stitched thread pairs
and enclosing thread pairs, such that, for example, the first
plurality is enclosed by a second plurality, which is enclosed by a
third plurality, which is enclosed by a fourth plurality, and so
forth. This process produces stable embroidered structures which do
not unravel into a pile of threads if the substrate is removed.
If the substrate is intended to be removed, the removal process is
dependent upon the material from which the substrate is composed.
If dissolution is the removal method chosen, the substrate
materials are chosen such that the process which dissolves the
substrate will minimally affect the physical properties of the
stitching or backing threads used in the embroidered structure.
When the substrate is removed, only the stitching and backing
threads remain, in whatever combination of thread pairs and
enclosing thread pairs that were utilized. The embroidered
structure remains intact despite the removal of the substrate
because each stitching thread is stitched to its corresponding
backing thread, and vice versa, which is enclosed in one or more
pluralities of enclosing thread pairs, all of which provides
structural support.
In some applications, it may be advantageous to have an
independent, unpaired thread, referred to as a "lace," existing
within an embroidered structure. Based upon the methodology of
embroidered structure creation above, however, any lace within an
embroidered structure would have to be placed after completion of
the embroidery process because all threads are stitched, and thus
paired, during the embroidery process. On a basic level, one or
more laces may be added to an embroidered structure by hand, but
this is possible only with the simplest of embroidered structures.
The manual placement of laces is also expensive, not easily
repeatable, and not conducive to mass production.
Repeatability is paramount in medical applications because devices
may work reliably in one configuration, but variations of such a
configuration may cause the device to perform unreliably,
inadequately, or even fail to perform altogether. Repeatable
placement of a lace within an embroidered structure used for
surgical implantation requires a level of reproducibility exceeding
that which may be achieved manually. Repeatability notwithstanding,
the expense required to manually add one or more laces to
embroidered structures further limits the use of manual insertion
techniques, as does the bottleneck such manual insertions would
cause in a manufacturing environment.
The present invention overcomes, or at least minimizes, the
limitations associated with placing one or more laces within an
embroidered structure.
SUMMARY OF THE INVENTION
According to the present invention, there is provided a
manufacturing process by which an embroidered structure may be
created containing within the structure one or more independent,
unpaired threads laces, in a manner which is repeatable,
inexpensive, and conducive to mass production.
The advantages to placing laces using the process of the present
invention are: (1) ease of manufacture of complex devices; (2) the
ability to make more complex devices; (3) the ability to improve
the repeatability of strength critical items; (4) the ability to
pre-load seams; and (5) the ability to create three-dimensional
shapes.
The process of the present invention may use any of a variety of
commercially available, automated embroidery machines and/or any
other non-manual technique used to manufacture embroidered
structures. A soluble thread composed of acetate (for example) or
other soluble material is used as the corresponding partner thread
for the lace thread during the embroidery process. The lace thread
is stitched with the soluble thread, forming in the embroidered
structure a temporary thread pair in the same creation process in
which all the other threads in the embroidered structure are
stitched. The soluble thread may be either the stitching thread or
backing thread, and thus the lace may be placed into the
embroidered structure as either the stitching or backing
thread.
After the stitching of the embroidered structure is complete, the
soluble thread is dissolved. The dissolution process used must be
suitable for dissolving the material of the soluble thread and
should preferably not negatively alter the physical properties of
the lace and other threads in the embroidered structure. Once the
soluble thread is removed, the temporary thread pair formed by the
soluble thread being stitched with the lace ceases to exist, and
the lace is no longer a part of the support system of the
embroidered structure. This leaves the lace as a single, unpaired
thread within the embroidered structure of paired threads.
Removal of the substrate may be done before, during and/or after
the dissolution of the soluble thread, depending upon the
properties of the materials used for the substrate and soluble
thread and any specific manufacturing concerns compelling the
sequence of removal. If dissolution is the method of removal
selected, the dissolution processes for the substrate will not only
depend upon the substrate material, but also the material of the
soluble threads, laces and other threads in the embroidered
structure to ensure that the process only affects the materials
targeted by the process.
Since the lace was a part of the embroidered structure as it was
being created and not placed from outside the otherwise finished
embroidered structure, and because the creation was performed
non-manually, the positional repeatability of the lace within the
embroidered structure is high. The replacement of standard threads
with soluble threads and the addition of a process to remove the
soluble thread, if not removed during a substrate dissolution
process, only nominally increases the cost of manufacturing with
laces as opposed to without, and the cost increase is significantly
less that of the cost of placing laces by hand. Finally, since the
method of creation may be automated using commercially available
embroidery machines, the embroidered structures containing laces
may be mass produced. Thus, the present invention overcomes, or at
a minimum improves upon, the limitations associated with
repeatability, expense, and mass producibility inherent to the
prior art.
BRIEF DESCRIPTION OF THE DRAWINGS
Many advantages of the present invention will be apparent to those
skilled in the art with a reading of this specification in
conjunction with the attached drawings, wherein like reference
numerals are applied to like elements and wherein:
FIG. 1 is a flow chart depicting one example of a general process
of placing laces in embroidered structures using one or more
soluble threads, according to one embodiment of the present
invention;
FIG. 2 is a perspective view one example of an embroidered
structure having a plurality of thread pairs, including a temporary
thread pair, formed according to the process of FIG. 1;
FIG. 3 is a plan view of a soluble thread stitched to a lace thread
to form the temporary thread pair of FIG. 2;
FIG. 4 is a perspective view of the embroidered structure of FIG. 2
after enclosing thread pairs are used to enclose the initial thread
pairs and temporary thread pair;
FIG. 5 is a perspective view of the embroidered structure of FIG. 4
after dissolution of the soluble thread and removal of the
substrate;
FIG. 6 is a plan view depicting one example of a generally flat
embroidered structure containing multiple laces manufactured
according to the process of FIG. 1;
FIG. 7 is a perspective view of a three-dimensional curved
embroidered structure formed by tensioning the laces of the
embroidered structure shown in FIG. 6;
FIG. 8 is a plan view depicting a second example of a generally
flat embroidered structure containing multiple laces manufactured
according to the process of FIG. 1;
FIG. 9 is a perspective view of a generally cylindrical embroidered
structure formed by tensioning and tying opposite ends of the laces
of the embroidered structure shown in FIG. 8;
FIG. 10 is a plan view of a third example of a generally flat
embroidered structure containing a single lace running through the
embroidered structure multiple times manufactured according to the
process of FIG. 1;
FIG. 11 is a perspective view of a generally cylindrical
embroidered structure formed by tensioning the lace of the
embroidered structure shown in FIG. 10;
FIG. 12 is a plan view of a fourth example of a generally flat
embroidered structure containing multiple laces manufactured
according to the process of FIG. 1;
FIG. 13 is a perspective view of a polygonal-shaped embroidered
structure, with one side open, formed by tying opposite ends of the
laces of the embroidered structure in FIG. 12;
FIG. 14 is a plan view of a fifth example of a generally flat
embroidered structure containing multiple laces manufactured
according to the process of FIG. 1;
FIG. 15 is a perspective view of a closed polygonal-shaped
embroidered structure formed by tying opposite ends of the laces of
the embroidered structure in FIG. 14;
FIG. 16 is a plan view of a system manufactured according to the
process of FIG. 1, including a series of individual embroidered
structures which act as anchors for one or more laces running
through the series of embroidered structures according to one
embodiment of the present invention;
FIG. 17 is a perspective view of an embroidered structure
manufactured according to the process of FIG. 1, through which one
or more laces are guided and thus prevented from crossing each
other while being positioned along the curve of an object according
to one embodiment of the present invention;
FIG. 18 is a plan view of a system manufactured by the process of
FIG. 1, including a series of embroidered structures with a single,
integral lace running through each which, upon tensioning, causes
the inwardly facing side surfaces of the embroidered structures to
pull into a uniform line according to one embodiment of the present
invention;
FIG. 19 is a plan view of an embroidered structure, manufactured
according to the process of FIG. 1, in which laces are interlaced
in a honeycomb pattern according to one exemplary aspect of the
invention;
FIG. 20 is a plan view of an embroidered structure, manufactured
according to the process of FIG. 1, in which laces are interlaced
in a diagonal weave pattern according to another exemplary aspect
of the invention;
FIG. 21 is a plan view of a pair of embroidered structures,
manufactured according to the process of FIG. 1, which are
connected by a single, preloaded lace according to one embodiment
of the present invention;
FIG. 22 is a plan view of the pair of embroidered structures of
FIG. 21, showing in particular that the seam of the embroidered
structure in FIG. 21 may be used to reproducibly unite objects (not
shown) connected to the embroidered structures upon tensioning of
the lace according to one embodiment of the present invention;
FIG. 23 is a plan view of a pair of embroidered structures,
manufactured according to the process of FIG. 1, which are
connected by two or more preloaded laces, according to one
embodiment of the present invention;
FIG. 24 is a plan view of the pair of embroidered structures of
FIG. 23, showing in particular that the seam of the embroidered
structure in FIG. 23 may be used to reproducibly unite objects (not
shown) connected to the embroidered structures upon tensioning of
the laces according to one embodiment of the present invention;
and
FIG. 25 is a plan view of a load bearing strap manufactured
according to the process of FIG. 1.
DESCRIPTION OF PREFERRED EMBODIMENT
Illustrative embodiments of the invention are described below. In
the interest of clarity, not all features of an actual
implementation are described in this specification. It will of
course be appreciated that in the development of any such actual
embodiment, numerous implementation-specific decisions must be made
to achieve the developers' specific goals, such as compliance with
system-related and business-related constraints, which will vary
from one implementation to another. Moreover, it will be
appreciated that such a development effort might be complex and
time-consuming, but would nevertheless be a routine undertaking for
those of ordinary skill in the art having the benefit of this
disclosure. The process of embroidery with soluble thread disclosed
herein boasts a variety of inventive features and components that
warrant patent protection, both individually and in
combination.
FIG. 1 outlines the one example of the process of manufacturing an
embroidered structure using soluble thread according to one
embodiment of the present invention. The process begins with a
substrate, upon which a plurality of backing threads are placed and
secured on one side, called the backing surface. A soluble thread
may be substituted for any backing thread within the plurality of
backing threads. For each backing thread on the backing surface of
the substrate, there is a corresponding stitching thread on the
opposing side of the substrate, called the stitching surface. A
soluble thread may be substituted for any stitching thread within
the plurality of stitching threads. Any soluble thread, used on
either the backing surface or the stitching surface, will
correspond to a lace on the opposing surface. Laces may be
physically identical to the stitching threads or backing threads or
may be composed of different materials or possess different
physical properties than the stitching threads or backing
threads.
Stitching may be done between one pair of threads at a time or in
simultaneous multiplicity, as is described below. The plurality of
stitching threads, lace threads, and/or soluble threads on the
stitching surface are passed from the stitching surface to the
backing surface, making openings in the substrate for each
individual thread, to meet with corresponding backing threads,
soluble threads, and/or laces on the backing surface. Each
stitching thread, lace, and/or soluble thread from the stitching
surface is then looped over its corresponding backing thread,
soluble thread, and/or laces on the backing surface. In essence,
this looping over engages or "picks up" each thread from the
backing surface, creating a "lock stitch." Once each thread from
the stitching surface has picked up its corresponding thread from
the backing surface, the plurality of threads originating from the
stitching surface are returned from the backing surface to the
stitching surface through the same openings made upon initial
passage through the substrate from the stitching surface. The lock
stitch prevents the threads from completely pulling out of the
openings made when returning to the stitching surface through the
substrate.
The process then repeats at a distance from the last stitch site,
and continues to repeat until each thread from the stitching
surface and its corresponding thread from the backing surface are
joined by lock stitches over a desired length. The end result is a
plurality of stitching threads stitched to backing threads in
thread pairs held together by lock stitches. Each thread pair is
parallel to the rest of the thread pairs on the substrate. Also
parallel to the thread pairs are the one or more temporary thread
pairs formed by stitching laces to corresponding soluble
threads.
A plurality of parallel stitched thread pairs and temporary thread
pairs may be enclosed by enclosing thread pairs. To enclose a
previously stitched plurality of thread pairs and temporary thread
pairs, the embroidery process above is repeated over the previous
embroidery already on the substrate. This process may be repeated
further by embroidering subsequent pluralities of enclosing thread
pairs over each other in a manner such that the first plurality of
enclosing thread pairs is enclosed by the second plurality of
enclosing thread pairs, which is enclosed by a third plurality,
which is enclosed by a fourth plurality, and so forth. This process
of producing embroidered structures containing multiple pluralities
of enclosing thread pairs results in stable embroidered structures
which do not unravel into a pile of threads upon removal of the
substrate.
The process of substrate removal, if not omitted, is dependent upon
the material from which the substrate is composed. Removal of the
substrate may be done before, after or simultaneously with the
dissolution of the soluble thread(s). If dissolution is the chosen
method or removal, the selection of materials used to form the
substrate and soluble thread will be in part compelled by any
manufacturing concerns regarding the sequence of dissolution.
Substrate and soluble thread materials are chosen such that the
process or processes which dissolve the substrate and soluble
thread will not negatively alter the physical properties of the
stitching threads, backing threads, and/or laces.
If the substrate is removed and the soluble threads are dissolved,
only the stitching threads, backing threads, and/or laces will
remain. The embroidered structure remains intact despite the
removal of the substrate because each stitching thread is stitched
to its corresponding backing thread, and vice versa, which is
enclosed in one or more pluralities of enclosing thread pairs, all
of which provides structural support. Once both the soluble threads
and substrate are removed, the laces are no longer a part of the
support system of the embroidered structure because the temporary
thread pairs cease to exist when the soluble threads are dissolved,
leaving the laces as single, unpaired threads within the
embroidered structure.
FIG. 2 is an example of an embroidered structure 10 during creation
by the process of manufacture according to one embodiment of the
present invention. Each thread pair 20 is created by stitching
together a stitching thread 11 and a backing thread 13 to form lock
stitches 15 on a substrate 16. The temporary thread pair 30 is
created by stitching together a lace 12 and a soluble thread 14 to
form lock stitches 15.
FIG. 3 is a closer view of the temporary thread pair 30 from the
embroidered structure 10 in FIG. 2. The lace 12 is substituted for
a stitching thread and has passed from the stitching surface 18,
creating an opening 19 through the substrate 16, to the backing
surface 17. There it engaged the soluble thread 14 forming a lock
stitch 15 and returned to the stitching surface 18 through the same
opening 19. This process is repeated at intervals along the path of
the soluble thread 14 until the desired length of stitching has
been achieved. Although the lace 12 has been substituted for a
stitching thread in this embodiment, the inverse is equally
applicable, where a soluble thread 14 could be substituted for a
stitching thread to form a temporary thread pair 30 with a lace 12
having been substituted for a backing thread.
FIG. 4 depicts the embroidered structure 10 created by enclosing
the thread pairs 20 and temporary thread pair 30 from FIG. 2 with
enclosing thread pairs 22. The enclosing thread pairs 22 contain
enclosing backing threads 23 and enclosing stitching threads 21.
The enclosing backing threads 23 are placed and secured on the
backing surface of the substrate 16 over the thread pairs 20 and
temporary thread pair 30. The enclosing stitching threads 21 are
stitched from over the thread pairs 20 and temporary thread pair 30
on the stitching surface 18 of the substrate 16 by the process
discussed above. The result is an embroidered structure 10 where
thread pairs 20 and temporary thread pairs 30 are enclosed within
the enclosing thread pairs 22.
The embroidered structure 10 is shown by way of example enclosed by
a first plurality of enclosing thread pairs 22. The same stitching
process or a different stitching process may be repeated or
performed one or more times using the same or different thread
materials to enclose thread pairs 20 and temporary thread pairs 30
by multiple pluralities of enclosing thread pairs 22 such that each
subsequent plurality of enclosing thread pairs encloses all thread
pairs 20, temporary thread pairs 30 and previous enclosing thread
pairs 22 over which it is embroidered.
FIG. 5 shows the embroidered structure 10 from FIG. 4 after
dissolution of the soluble thread 14 and dissolvable substrate 16.
Once the structure 10 from FIG. 4 is embroidered with the desired
number of thread pairs 20 and temporary thread pairs 30, and
enclosed by the desired number of enclosing thread pairs 22, the
soluble thread 14 may be dissolved and the substrate 16 may be
removed. The dissolution of the soluble thread 14 and removal of
the substrate 16 may be done in the same or different processes,
and in any order. If dissolution is the chosen method of substrate
removal, the dissolution processes will depend upon the composition
of the soluble threads 14 and the stitching threads 11, laces 12,
backing threads 13, enclosing stitching threads 21, and enclosing
backing threads 23 as well as the composition of the substrate 16
upon which the embroidered structure 10 was created. These
compositions are application dependent and different materials may
be used according to not only dissolution processes, but also the
function of the completed embroidered structure 10. After
dissolution of the soluble thread 14 and substrate 16 is completed,
the lace 12 is no longer a part of a temporary thread pair, and
thus is unpaired within the embroidered structure 10.
FIGS. 6-25 illustrate multiple embodiments of embroidered
structures created using the manufacturing process described above.
For the purposes of simplicity and consistency, features common to
those shown and described in relation to embroidered structure 10
of FIGS. 2-5 are designated with common numbers.
FIG. 6 depicts an example of an embroidered structure 40 according
to a first embodiment of the present invention. The embroidered
structure 40 is shown by way of example as being generally flat,
having a generally circular shape, and containing a series of laces
12 placed into the embroidery by the process of manufacture
described above. The laces 12 are substituted for some of the
stitching threads and soluble threads are substituted for the
corresponding backing threads. The lace threads 12 and soluble
threads are then stitched together forming temporary thread pairs
while the remaining stitching threads and backing threads are
stitched together forming a plurality of thread pairs 20. The
thread pairs 20 and temporary thread pairs may then be enclosed by
enclosing thread pairs 22 formed from enclosing stitching threads
and enclosing backing threads. When the embroidering is completed,
the soluble threads may be dissolved and the substrate may be
removed. After dissolution of the soluble threads and removal of
the substrate, the laces 12 will no longer be paired and will be
free to move through the embroidered structure 10. Surrounding
structures may be engineered to form eyelets for the laces 12 to
run through.
FIG. 7 illustrates the effect of tensioning the multiple laces 12
contained in the embroidered structure 40 from FIG. 6. Tensioning
the laces 12 decreases the circumference of the generally circular
path in which the laces 12 run around the fixed area of embroidered
thread pairs 20 and enclosing thread pairs 22. This decreased
circumference causes doming as the fixed area takes the
three-dimensional shape due to the constraining of the fixed
embroidered area within the decreased lace 12 circumference.
FIG. 8 depicts an example of an embroidered structure 50 according
to a second embodiment of the present invention. The embroidered
structure 50 is shown by way of example as being a generally flat,
generally rectangular structure through which more than one lace 12
has been placed by the process of manufacture described above. The
rectangular embroidered structure 50 necessarily has four edges;
two shorter edges 52 and two longer edges 54. In this embodiment,
the laces 12 run parallel to the two short edges 52 from one long
edge 54 to the other long edge 54. Alternatively, the embroidered
structure 50 could be arranged such that the laces 12 could run
between short edges 54 parallel to the long edges 52, in which case
the resulting cylindrical shape (see below) would be short and
wide.
FIG. 9 illustrates the effect of tensioning and tying together the
opposing ends of the laces 12 contained within the embroidered
structure 50 from FIG. 8. The laces 12 as laid out in the
embroidered structure 50 in FIG. 8 are generally flat, straight
lines in the same plane as the stitched pairs 20 and enclosing
pairs 22. When opposite ends of the laces 12 are brought together
to make knots 24, the paths of the laces 12 becomes generally
circular rather than linear, as in FIG. 8. Since the laces 12 are
enclosed within the thread pairs 20 within the enclosing thread
pairs 22, putting the laces 12 into circular paths also pulls the
short edges 52 of the embroidered structure 50 into a generally
circular shape while drawing together the opposing long edges 54 of
the embroidered structure 50. Once the long edges 54 meet, the
opposing ends of each lace 12 are tied together in knots 24 to
secure the now cylindrical shape of the embroidered structure 50.
In forming the cylindrical structure, the short edges 52 become
generally circular and the long edges 54 meet to form a seam 56
which is parallel to the height aspect of the cylindrically shaped
embroidered structure 50.
FIG. 10 depicts an example of an embroidered structure 60 according
to a third embodiment of the present invention. The embroidered
structure 60 is shown by way of example as being a generally flat,
generally rectangular structure through which a single lace 12 was
placed multiple times by the process of manufacture described
above. The generally rectangular embroidered structure 60
necessarily has four edges; two short edges 62 and two long edges
64. In this embodiment, the lace 12 runs generally diagonally from
one long edge 64 to the other long edge 64, then around the outside
of the embroidered structure 60 and back to the first long edge 64
where it enters the embroidered structure again. In an alternative
embodiment, the lace 12 could be run between the short edges 62 to
result in a differently dimensioned structure than the one
described below.
As shown in FIG. 11, a three-dimensional, generally cylindrical
embroidered structure 60 may be formed by tensioning the lace 12 of
the embroidered structure 60 shown in FIG. 10. The lace 12 is laid
out in the shape of a flat spiral in FIG. 10, but as the lace 12 is
tensioned, the radii of the spiral loops of the lace 12 begin to
decrease until the two-dimensional lace 12 spiral takes the shape
of a three-dimensional helix. Since the lace 12 is enclosed within
the thread pairs 20 within the enclosing thread pairs 22, putting
the lace 12 in a helical shape causes the embroidered structure 10
enclosing it to curl around the axis of the spiral path of the lace
12. The curling causes the long edges 64 of the embroidered
structure 10 to come closer together such that the edges will
eventually meet. Once the long edges 64 meet, the embroidered
structure 60 is in the general shape of a cylinder with the long
edges 64 forming a seam 66 parallel to the axis of the helix and
the height aspect of the cylinder.
FIG. 12 depicts an example of an embroidered structure 70 according
to a fourth embodiment of the present invention. The embroidered
structure 70 is shown by way of example as being a generally flat,
polygonal shaped structure through which several laces 12 are
placed by the process of manufacture described above. The polygon
may have a central panel 72 which shares each of its sides with one
of four outer panels 74. The laces 12 are run through each of the
outer panels 74 without running through the central panel 72, such
that the lace 12 runs through one outer panel 74, then through open
space 76, then through another outer panel 74, then through open
space 76 and so on until the two ends of each lace 12 occupy the
same open space 76. In the example shown in FIG. 12, the central
panel 72 and outer panels 74 are all square shaped, and thus are
dimensionally identical to one another. However, it is contemplated
that any variety of complementary polygonal shapes and
configurations may be used, such as for example a generally
rectangular central panel 72 in combination with a pair of opposing
generally rectangular outer panels 72 and a pair or opposing
generally square outer panels 72. Such a configuration would result
in a generally rectangular box shape upon tensioning of the laces
12 (as described below). Further embodiments may include
combinations of triangles, quadrilaterals, pentagons, hexagons,
etc.
As shown in FIG. 13, a three-dimensional polyhedron open box-shaped
embroidered structure 70 may be formed by tensioning the laces 12
shown in FIG. 12. Tensioning the laces 12 pulls the length of each
lace 12 from the open space 76 between outer panels 74, which in
turn draws the edges of the outer panels 74 together. When all the
length of laces 12 between the outer panels 74 has been pulled
through the outer panels 74, the edges of the polygonal embroidered
structure 70 unite such that a polyhedron shaped embroidered
structure 70 with one open side is formed. Tying the opposite ends
of the laces 12 in knots 24 secures the shape of the embroidered
structure 70.
FIG. 14 depicts an example of an embroidered structure 80 according
to a fifth embodiment of the present invention. The embroidered
structure 80 is shown by way of example as being a generally flat,
polygonal-shaped structure enclosing a series of laces 12 placed
therein by the process of manufacture described above. The
polygonal shape may have a first major panel 82 which shares each
of its sides with one side of each of four minor panels 84a, 84b,
84c, and 84d. In the example shown, each of the four minor panels
84a-d is the same height, and has a length defined by the side it
shares with the first major panel 82. Minor panel 84c is positioned
between the first major panel 82 and a second major panel 86, in
that the minor panel 84c shares one length-defining side with the
first major panel 84 and a second, identical length-defining side
with the second major panel 86. By way of example only, the second
major panel 86 is identically dimensioned relative to the first
major panel 82. The laces 12 are distributed in three ways. The
laces 12a run lengthwise successively through the four minor panels
84a-d. The laces 12a originate in a first open space 88a, pass
through the first minor panel 84a in a lengthwise direction and
into a second open space 88b. This path continues in succession
through minor panel 84b, open space 88c, minor panel 84c, open
space 88d, and minor panel 84d until the laces 12a emerge within
open space 88a at which point both ends of each lace 12a are in the
same open space. The laces 12b pass into the second major panel 86,
straight through the minor panel 84c (and generally perpendicular
to the laces 12a therein), through the first major panel 82 and out
the end of the polygon through the minor panel 84a (and generally
perpendicular to the laces 12a therein). Laces 12c follow a
generally horseshoe-shaped path, for example entering minor panel
84d and passing through such that laces 12c are generally
perpendicular to laces 12a within minor panel 84d. Laces 12c
continue through major panel 82 (such that laces 12c are generally
perpendicular to laces 12b within major panel 82) and through the
minor panel 84b (also such that laces 12c are generally
perpendicular to laces 12a within minor panel 84b). Upon exiting
minor panel 84b, laces 12c curve back to the polygon to pass
through the major panel 86 in a direction generally parallel to the
laces 12c within major panel 82 and generally perpendicular to
laces 12b within major panel 86. Surrounding structures may be
engineered to form eyelets for the laces 12a-c to run through.
FIG. 15 shows the three-dimensional embroidered hexahedron
structure 80 created by tensioning and tying the opposite ends of
each laces 12a-c from FIG. 14. Upon tensioning the laces 12a, the
length of lace 12a in the open spaces 88a-d shorten, which in turn
pulls the edges of the minor panels 84a-d together. When all the
length of lace 12a between the minor panels 84a-d has been pulled
through the minor panels 84a-d, the edges of the polygonal
embroidered structure 80 unite to form a polyhedron-shaped
embroidered structure 80 with one open side, and with the major
panel 86 attached to an edge of the open side of the polyhedron
(minor panel 84c). Tying the opposite ends of the laces 12a in
knots 24a secures the shape of the embroidered structure 80.
Tensioning and tying laces 12b into knots 24b draws the major panel
86 on top of the open side, thus closing the open box structure by
adding the sixth side necessary to have a closed hexahedron.
Tensioning and tying laces 12c into knots 24c secures the last
remaining unfixed edge of the closed hexahedron.
FIG. 16 depicts a set of generally flat embroidered structures 90
according to a sixth embodiment of the present invention, used to
anchor and guide a lace 12 which runs through each of the
embroidered structures 90. The process for manufacturing the
embroidered structure 90 is described above. The completed
embroidered structures 90 may be affixed to a surface or surfaces
using the fastener holes 25 to facilitate mechanical attachment
between each embroidered structure 90 and the surface to which it
is joined. Once in place, the embroidered structures 90 act as
anchors and guide the lace 12 as it is pulled through the
embroidered structures 90. The predictability of the path of the
lace 12 allows for the lace 12 to be protected from fouling on
surrounding objects and protects surrounding objects from being
damaged or disturbed through contact with the lace 12.
FIG. 17 shows a generally flat embroidered structure 100 according
to a seventh embodiment of the present invention. The embroidered
structure 100 has a generally rectangular shape and is used to
guide laces 12 in a predictable path around an object. The process
for manufacturing the embroidered structure 100 is described above.
The completed embroidered structure 100 may be affixed to a surface
using the fastener holes 25 to facilitate mechanical attachment
between the embroidered structure 100 and the surface to which it
is joined. The embroidered structure 100 allows the laces 12 to be
guided in a predictable path when positioned partially around an
object, such as a generally cylindrical, generally polyhedral or
object of some other shape. This guided running prevents the laces
12 from crossing, which would inhibit their freedom of movement.
Surrounding structures may be engineered to form eyelets for the
laces 12 to run through.
FIG. 18 shows a set of generally flat embroidered structures 110
according to an eighth embodiment of the present invention, used to
reproducibly position objects in a line. The process for
manufacturing the embroidered structure 110 is described above. The
embroidered structures 110 are generally rectangular, and may have
one or more fastener holes 25. A single, integral lace 12 runs
through all of the embroidered structures 10, and may run through
the embroidered structures 12 either close to the facing sides,
over the fastener holes 25 along the periphery opposite the facing
sides or at any position there between. The completed embroidered
structures 110 may each be affixed to an object using the fastener
holes 25 to facilitate mechanical attachment between each
embroidered structure 110 and the object to which it is joined.
Once the embroidered structures are attached to objects, tensioning
the lace 12 by pulling its ends in opposite directions will cause
the lace 12 to straighten. As the lace 12 straightens, it will pull
the embroidered structures 110, and the objects to which they are
attached, into a line defined by the directions in which the two
ends of the lace 12 are pulled.
FIG. 19 depicts a woven structure 26 according to one aspect of the
present invention, created from laces 12 using the embroidery
techniques of the present invention. Each of the woven laces 12,
individually numbered L1-L40, is laid down by stitching to a
corresponding soluble thread on a substrate, forming temporary
thread pairs. When all of the laces 12 are stitched to
corresponding soluble threads, there is an embroidered structure of
temporary thread pairs on the substrate. The soluble threads may
then be dissolved and substrate may be removed. After dissolution
of the soluble thread and substrate, the pairing of the soluble
thread with the lace thread 12 is destroyed. As there are no longer
any paired threads, but instead only interwoven laces 12 holding
each other in the woven structure 26. The dissolution of the
soluble thread and substrate turn what is created as an embroidered
structure into a woven structure 26.
The woven structure 26 is exemplary of the use of the embroidering
techniques of the present invention to create non-embroidered
finished products. The extent of these non-embroidered products is
not limited to those which are woven, but includes all other
methods of creating structures from filamentary materials. The
finished products may be completely non-embroidered or a hybrid of
embroidery and one or more other techniques including, but not
limited to, weaving.
Woven structures may also take many shapes. For example, the woven
structure 26 from FIG. 19 is created by embroidering in the
following order and positions:
TABLE-US-00001 Lace Number and Stitching Order Orientation Location
L1 Vertical Centered L2 Horizontal Centered L3 Vertical Right of L1
L4 Horizontal Below L2 L5 Vertical Left of L1 L6 Horizontal Above
L2 L7 Vertical Right of L3 L8 Horizontal Below L4 L9 Vertical Left
of L5 L10 Horizontal Above L6 L11 Vertical Right of L7 L12
Horizontal Below L8 L13 Vertical Left of L9 L14 Horizontal Above
L10 L15 Vertical Right of L11 L16 Horizontal Below L12 L17 Vertical
Left of L13 L18 Horizontal Above L14 L19 Vertical Right of L15 L20
Horizontal Below L16 L21 Vertical Left of L17 L22 Horizontal Above
L18 L23 Vertical Right of L20 L24 Horizontal Below L30 L25 Vertical
Left of L21 L26 Horizontal Above L22 L27 Vertical Right of L23 L28
Horizontal Below L24 L29 Vertical Left of L25 L30 Horizontal Above
L26 L31 Vertical Right of L27 L32 Horizontal Below L28 L33 Vertical
Left of L29 L34 Horizontal Above L30 L35 Vertical Right of L31 L36
Horizontal Below L32 L37 Vertical Left of L33 L38 Horizontal Above
L34 L39 Vertical Right of L35 L40 Horizontal Below L36
This order and position creates a honeycomb-shaped woven structure
26. However, different weaving effects give structures different
properties, including but not limited to flexibility and feel.
FIG. 20 depicts a woven structure 26 created by the same process as
the woven structure in FIG. 19, differing only in the number,
order, and position of the laces 12 (individually numbered L1-L36).
The woven structure 26 in FIG. 20 is woven in the following order
and positions:
TABLE-US-00002 Lace Number and Stitching Order Orientation Location
L1 Vertical Left Edge L2 Horizontal Top Edge L3 Vertical Right of
L1 L4 Horizontal Below L2 L5 Vertical Btw L1 & L3 L6 Horizontal
Btw L2 & L4 L7 Vertical Right of L3 L8 Horizontal Below L4 L9
Vertical Between L3 & L7 L10 Horizontal Between L4 & L8 L11
Vertical Right of L7 L12 Horizontal Below L8 L13 Vertical Between
L7 & L11 L14 Horizontal Between L8 & L12 L15 Vertical Right
of L11 L16 Horizontal Below L12 L17 Vertical Between L11 & L13
L18 Horizontal Between L12 & L16 L19 Vertical Right of L15 L20
Horizontal Below L16 L21 Vertical Between L15 & L20 L22
Horizontal Between L16 & L30 L23 Vertical Right of L20 L24
Horizontal Below L30 L25 Vertical Between L20 & L23 L26
Horizontal Between L30 & L24 L27 Vertical Right of L23 L28
Horizontal Below L24 L29 Vertical Between L23 & L27 L30
Horizontal Between L24 & L28 L31 Vertical Right of L27 L32
Horizontal Below L28 L33 Vertical Between L27 & L31 L34
Horizontal Between L28 & L32 L35 Vertical Right of L31 L36
Horizontal Below L32
After dissolution of the soluble thread and substrate, this order
and position creates a diagonal weave throughout the woven
structure 26. This weave will have different characteristics,
including but not limited to flexibility and feel, than that of the
woven structure 26 in FIG. 19. The patterns from FIG. 19 and FIG.
20 are merely examples of the numerous patterns possible from
interlacing by the process of the present invention.
FIG. 21 shows a pair of embroidered structures 10 separated by a
seam preloaded with one lace 12 according one example of a ninth
embodiment of the present invention. The process for manufacturing
the embroidered structure 10 is described above. During the
embroidery process of the present invention, a lace 12 is stitched
to a soluble thread such that the temporary thread pair zigzags
between the pair of embroidered structures 10. Eyelet threads 28
are then sewn around the lace 12 and soluble thread on each of the
embroidered structures 10. The soluble thread and substrate are
then dissolved. The two embroidered structures 10 are now
independent of each other, and the lace 12, no longer a part of a
temporary thread pair after dissolution of the soluble thread, is
free to run through the eyelet threads 28 between the two
embroidered structures 10.
FIG. 22 illustrates the result of tensioning the lace 12 between
the embroidered structures 10 in FIG. 21. When tensioned, the lace
12 will pull into as straight a line as possible. This
straightening imparts a force from the lace 12 onto the embroidered
structures 10, drawing the embroidered structures 10 closer
together along the seam 27 separating them. When the embroidered
structures 10 are attached to two or more objects, this embodiment
provides a manner in which the attached objects may be united in a
highly consistent, repeatable manner.
FIG. 23 shows a pair of embroidered structures 10 separated by a
seam preloaded with more than one lace 12 by the process of the
present invention. After the embroidered structures are created
according to the process described in the explanation of FIG. 21
above, two or more laces 12 are stitched to soluble threads such
that the temporary thread pairs zigzag between the pair of
embroidered structures 10, one mirroring the path of the other.
Eyelet threads 28 are then sewn around the laces 12 and soluble
threads on each of the embroidered structures 10. The soluble
threads and substrate are then dissolved. The two embroidered
structures 10 are now independent of each other and the laces 12,
no longer a part of temporary thread pairs after dissolution of the
soluble threads, are free to run through the eyelet threads 28
between the two embroidered structures 10.
FIG. 24 illustrates the result of tensioning the laces 12 between
the embroidered structures 10 in FIG. 23. As in the single lace
version in FIG. 22 above, the tensioned laces 12 will pull into as
straight a line as possible. This imparts a force from the laces
onto the embroidered structures 10, drawing them closer together
along the seam 27 separating them. When the embroidered structures
10 are attached to two or more objects, this embodiment provides a
manner in which the attached objects may be united in a highly
consistent, repeatable manner.
FIG. 25 shows an embroidered structure 10 manufactured according to
one embodiment of the present invention in the form of a load
bearing structure. During the embroidery process of the present
invention, the lace 12 is stitched to a soluble thread on a
substrate. The whipping thread 31 is then stitched around the lace
12 and soluble thread such that the whipping thread 31 will hold
the stem of the embroidered structure 10 together. The dissolution
of the soluble threads and dissolvable substrate may be performed
once the stitching of the embroidered structure 10 has been
completed. After dissolution, the embroidered structure 10 may be
used as a load bearing device such as by coupling the resulting
loops 29 between two structures or two regions within a single
structure. The use of the embroidery techniques in the production
of the embroidered structure 10 ensures the uniformity of the free
loops 29 and the equalized length of the lace 12, thus improving
the consistency of performance of embroidered structures 10 through
the repeatability of its manufacture.
As evidenced above, the present invention overcomes, or at least
minimizes, the drawbacks of the prior art. The devices described
herein may be repeatably mass produced based on the automated
nature of the embroidery process of the present invention.
Embroidery with one soluble thread allows for a single, unpaired
lace to be laid down reliably, cost effectively, and in a manner
conducive to mass production.
While the invention is susceptible to various modifications and
alternative forms, specific embodiments thereof have been shown by
way of example in the drawings and are herein described in detail.
It should be understood, however, that the description herein of
specific embodiments is not intended to limit the invention to the
particular forms disclosed, but on the contrary, the invention is
to cover all modifications, equivalents, and alternatives falling
within the spirit and scope of the invention as defined herein.
* * * * *